Saturn NHC 25B/30B/41B User manual

Installation, Maintenance and User Guide
Instruction Manual
Instruction Manual
Read the instructions fully before installing or using the appliance.
INSTALLER, this manual is to be axed adjacent to the boiler.
CONSUMER, retain this manual for future reference purposes.
Constant development eorts may result in minor deviations in
illustrations, functional steps and technical data without prior notice.
Pictures and drawings in the instructions can be dierent from the
appliance. All product images are provided by the manufacturer and are
for reference purposes only.
NHC 25B/30B/41B (Boiler House w/ Combi Option)
NHC 25E/30E/41E (External w/ Combi Option)
NHC 25H/30H/41H (Boiler House w/ Heat Only)
NHC 25EH/30EH/41EH (External w/ Heat Only)

Contents
Homeowner
4
5
6
7
8
9
10
11
12
13
14
18
20
22
23
24
26
30
31
36
37
42
43
44
45
Safety instructions
Product Fiche
Operation & Display Panel (OBC100)
Room Thermostat (LCR-2WE) - Combi Only
Vacation/Standby Mode - Combi only
Heating Mode - Combi only
Hot water Mode - Combi only
Fault Codes
Installer
Design Standards
Safety
Flue Regulations
Before Using The Boiler
How To Use
Safety Devices
Everyday Checks
Servicing The Boiler
Plumbing Schematic
Commissioning The Boiler
Component Overview
Electric Wiring Diagram
Wiring - Installation Variations
OTC Mode
Troubleshooting
Fault Codes
Product Information
Spare Parts
Specifications
Warranty
46
49
50

4
Safety Instructions
Safety-related messages and instructions have been provided in this manual
and on the boiler to warn you and others of a potential injury hazard. Read
and follow all safety messages and instructions throughout this manual.
It is very important to understand this safety section for operating,
installing and servicing of the boiler.
In addition to this, under the Consumer Protection Act 1987 and Section
6 of the Health & Safety Act 1974, we are required to provide
information on substances hazardous to health.
The small quantities of adhesives and sealants used in the product are
cured. They present no known hazards when used in the manner for
which they are intended.
This is a safety alert symbol. It is used to alert you to potential
personal injury hazards.
Obey all safety messages that follow this symbol to avoid
possible injury or death.
Indicates an imminently hazardous situation which
if not avoided, could result in severe injury or death.
Indicates a potentially hazardous situation which,
if not avoided, could result in severe injury or death.
Indicates an imminently hazardous situation which,
if not avoided, could result in minor moderate injury.
Earth
Use of fire
forbidden
Dangerous
electric current

Product Fiche
5
KD Navien Unit NHC 25B NHC 30B NHC 41B
Space heating : temperature application Medium Medium Medium
XL XL XXL
A A A
B B B
Rated heat output kW 24.0 27.9 36.8
Space heating : annual energy consumption kWh 76 89 116
Water heating : annual electricity consumption(Combi only) kWh 94 93 105
Water heating : annual fuel consumption(Combi only) GJ 22 23 30
% 91 90 91
% 64 62 67
Sound power level dB 68 66 69
Read the user's information and installation
manual before the application is assembled,
installed or maintained.

LCD indicate the temp of heating water,
the value of K-Factor, and occurrence of
trouble displayed the failure code.
*See page 11 for Error Code Table
LCR-2WE Programmer- Combi only
The LCR-2WE remote control panel will
activate by pushing the power on/off button.
6
Operation and display panel (OBC100)

7
Hot water Temperature
(Lo/Mid/Hi)
Standby
Mode
Heating
Mode
Hot water
Mode
Temperature Operation
Indicator
Indicating each
function and status
LCD Display
Room Thermostat
Power ON/OFF
Power
Heating Mode
Heating
Adjusting Temp.
Up/Down
Standby Setting Mode
Standby Mode
Hot Water Mode
Hot Water
Operation/Service
LED Lamp
Room Thermostat (LCR-2WE) - Combi only
LCD

If you are not at home, you can set the Standby Mode to save heating
energyby pressing.
To cancelvacation/standby mode press the
button to return to the heating mode.
will be displayed and Standby Mode
will be set.
Press button.
8
Vacation/Standby Mode - Combi only

blinks when selecting
Boiler Temp. Mode
when blinks, set the desired
boiler temp. between40~80˚C by
adjusting / button, after awhile,
it is automatically saved. Boiler
temp. can be set by 1˚C. After the
required temperature has been
selected, is on and current
boiler water temp. is displayed.
Set the heating temp.
with /button.
Press the button.
The LCR-2WE room thermostat is designed to control a heating system
according to time and temperature, in connection with a valve controller
(red colored cable).
9
Heating mode - Combi only

will be displayed and
Hot Water Mode will be set.
Adjusting hot water temp. by
3step; Low load, Medium load,
High load capacity of
combustion.
Set the heating temp.
with / button.
Use this function only when hot water is needed.
1. Please be careful that infants and young children do not use
hot water without a guardian present.
2. While others are using hot water, do not change the hot
water temp. setting for safety.
CAUTION
Press button.
You can determine whether the changeover
from DHW mode to Heating mode by
pushing “ " button.
10
Hot Water Mode - Combi only

Fault at the boiler
Fault codes take priority over all other display functions in the event of a system
fault occurring and the LCD shows one of the following numeric error codes.
If multiple faults occur, the corresponding fault codes are displayed alternately
for about two seconds each.
To reset the boiler switch the power button on -> off -> on.
If problem persists, contact your local installer.
02
03
04
05
06
12
16
Low water level
Temp. sensor wire
disconnected
Short circuit of
Temp. sensor
High limit thermostat
Error Code Cause
Fault at the room controller
51
52
Electrical backup system
failure
Functional button
defective
Error Code Cause
Electrical backup
The LCR-2WE retains the setting
parameterswhen the power
or shut down bypower outages
andback to the preset operation.
11
Fault Codes

12
Design Standards
EMC Directive (Electromagnetic compatibility) 89/336/EC
Standards:
EN 61000-6-1: Electromagnetic Compatibility Generic Standard –
Immunity for residential, commercial and light industrial environments.
(Feb 2001)
EN 61000-6-3: Electromagnetic Compatibility Generic Standard – Emission
standard for residential, commercial and light industrial environments.
(Feb 2001)
LV Directive (Low voltage) 73/23/EEC
Standard:
EN 60335-1: Household and similar electrical appliances - Safety (May
2001)
Boiler Efficiency Directive 92/42/EEC
Standard:
BSEN 304: Oil boilers with forced draft burners.
Fuel Spillage
1. Switch off all electrical and other ignition sources.
2. Remove all contaminated clothing to safeguard against fire risk and skin
damage. Wash affected skin thoroughly with soap and water and remove
clothing to a safe well ventilated area and allow to air before cleaning.
3. Contain and smother the spill using sand or other suitable oil absorbent
media or non-combustible material.
4. Do not allow fuel to escape into drains or water courses. If this happens,
contact the relevant authorities in your area. (Ireland only). Contact the
Environment Agency on 0800 807060 (UK Only)
5. Consult local authority about disposal of contaminated soil, see
http://www.housing.gov.ie/local-government/administration/local-
authorities/local-authorities
INSTALLER SECTION

13
Safety
Safe use of kerosene.
These fuels give off a flammable vapour when heated moderately. Vapour ignites
easily, burns intensely and may cause explosion. The vapour can follow along at
ground level for considerable distances from open containers and spillages
collecting as an explosive mixture in drains, cellars, etc.
Fuels remove natural oils and fats from the skin and this may cause irritation and
cracking of skin. Barrier cream containing lanolin is highly recommended together
with good personal hygiene and where necessary appropriate personal protection
equipment. (P.P.E.) Gas oil may also cause irreversible damage to health on
prolonged or repeated skin contact.
Always store fuels in a properly constructed and labelled tank. Always handle fuel in
open air or well ventilated space away from sources of ignition and refrain from
smoking.
Always drain fuel using a proper fuel retriever, funnel or mechanical siphon. Never
apply heat to a fuel tank, container or pipework. Never siphon fuel through tube by
mouth. If accidentally swallowed contact doctor immediately and do NOT induce
vomiting. Avoid inhaling fuel vapour as this can cause light headedness and
seriously impair judgement.
First Aid
If fuel is accidently swallowed:
Seek medical attention immediately and DO NOT induce vomiting.
If fuel is splashed into your eyes:
Wash out with running water for at least ten minutes and seek medical attention as
soon as possible.

14
Flues Regulations
Balanced Flue Siting
Note:
1. Terminal should be positioned to avoid combustion products entering the building
or accumulating in stagnant pockets around buildings.
2. The terminal must be protected by a guard if it is less than 2 metres above ground
level or in a position where any person has access.
3. A heat protection shield should be fitted if the terminal is less than 850mm from a
plastic or painted gutter or less than 450mm from painted eaves.
Saturn Heating recommends as per OFTEC recommendations that the flue should
be a minimum distance of 1 metre from openings so that it does not cause a
nuisance and permits the dispersal of combustion products.
Building Regulations A B C
Northern Ireland 600 600 600
Republic of Ireland 600 600 600
Where the terminal is within 1 metre of any plastic material, such material should be
protected from the effects of combustion products of fuel. There are additional general
requirements in most regulations and standards that the flue must be positioned so that it
does not cause a nuisance and permits the dispersal of combustion products.
Note: The Building Regulations clearances shown above are the minimum allowed.
Contact Saturn Heating Technical Department for futher advice in this regard.
ALWAYS CHECK FOR ANY BUILDING REGULATIONS AMENDMENTS WHICH
MAY HAVE BEEN ISSUED AFTER THE PUBLICATION OF THIS MANUAL
a) Horizontal from opening,
airbrick, opening window
etc.
b) From an internal or external
corner.
c) Below an opening, airbrick,
opening window etc.
Information supplied by
Book Four, 2010.
Please see note at foot of page.

15
Flues Regulations
Clearances advised by the British Standards, provided by OFTEC, for open flues, low level
balanced flues and balanced flues fitted to oil fired boilers.
Minimum distances to terminals in millimetres as measured from top of the chimney or
the rim of a low level discharge opening.
Aplliance Burner Type
Pressure
Jet
Vapourising
A
Directly below an opening, air brick, opening window etc
600
Not allowed
B
Horizontally to an opening, air brick, opening window etc
600
Not allowed
C
Below a gutter, eaves or balcony without protection
75
Not allowed
D
Below a gutter or a balcony without protection
600
Not allowed
E
From vertical sanitary pipework
300
Not allowed
F
From an internal or external corner or surface or boundary
alongside the terminal
300
Not allowed
G
Above ground or balcony level
300
Not allowed
H
From a surface or boundary facing the terminal
600
Not allowed
J
From a terminal facing a terminal
1200
Not allowed
K
Vertically from a terminal on the same wall
1500
Not allowed
L
Horizontally from a terminal on the same wall
750
Not allowed
M
Above the highest point of an intersection with the roof
600
1000
N
From a vertical structure on the side of the terminal
750
2300
O
Above a vertical structure less than 750mm from the side of the
terminal
600
1000
P
Directly below an opening, air brick, opening window etc.
1500
Not allowed
Notes:
-Terminals should be positioned so asto avoid products of combustion accumulating in
stagnant pockets around the building orentering into buildings.
-Appliances burning Class D oil have additional restrictions (See OFTEC Book 42010)
-Vertical structure in N, O and P include tank orlift rooms, parapets, dormers etc.

16
Flues Regulations
-Terminating positions A to L are only permitted for appliances that have been approved
for low level flue discharge when tested to OFS A100 or A101
-Terminating positions must be at least 1.8 metres distant from an oil storage tank unless
a wall with at least 30 mins fire resistance and extending 300mm higher and wider than the
tank is provided between the tank and the terminating position.
-Where a flue is terminated less than 600mm away from a projection above it and the
projection consists of plastic or has a combustible or painted surface, then a heat shield of
at least 750mm wide should be fitted to protect these surfaces.
-For terminals used with vapourising burners, a horizontal distance of at least 2300mm is
required between the terminal and the roof line.
-If the lowest part of the terminal is less than 2 metres above the ground, balcony, flat
roof or other place to which any person has access, the terminal must be protected by a
guard.
- Notwithstanding the dimensions given in the drawing and table, a terminal should not be
sited closer than 300mm to combustible material.
Ventilation & Combustion Air
Conventional Flue Boilers
An adequate supply of combustion and ventilation air is essential for efficient and safe
boiler operation and the openings for this should be positioned to cause least possible
draught, with no possibility of being accidentally blocked. Please note, the British Standard
Code of Practice for Oil Firing BS5410:Part 1, requires a permanent air inlet opening of
550mm ²per kW (above 5kW) of boiler rated output. (Note: 1kW = 3412 Btu/h).
Also when the boiler is installed in a compartment or confined space, ventilation openings are
required to ventilate and to avoid overheating in the boiler area.
FULL TEXT of both BS 5410 Part 1: 1997 and appropriate Building Regulations for each country
should be obtained and fully applied.

17
Flues Regulations
N.B. Please Carefully Note:
In OFTEC Book Four,2010 page 33, 6.6.5 states that for the Republic of Ireland, “It is
not permitted to install open flue appliances in domestic garages, therefore only room
sealed balance flue appliances should be installed in a garage location”
Definitions:
Combustion Air: Air required directly by boiler oil burner for combustion process.
Ventilation Air: Air required in the room for ventilation, cooling, etc. and to promote a
healthy living environment.

Check all pipe connections thoroughly for
leaks before start-up.
Before using the boiler
18
Fuel
It is essential to use only kerosene or light oil.
It is better to use kerosene when the temperature
can drop below -5 ˚C.
Choose a fuel storage location in accordance with
local regulations (See page 14 - Flue Regulations).
Take care to avoid the ingress of water and/or dirt
during re-lling as this can lead to flame failure or
aect the lifespan of the boiler.
Ensure that the power is turned oand
the oil tank is isolated before relling.
A fuel filter with a filter rating of 70microns or
better must be fitted to the fuel supply, to the
appliance.
Pre-Start Checks

and that the low water level alarm is not activated.
suitable measurement equipment to ensure
correct combustion is taking place.
Do not plug out the power supply as this will
de-activate the frost protection.
The domestic hot water supply is not
recommended for potable use.(Combi only)
19
Notes when using
Take care when positioning the boiler.
Do not locate in the immediate
vicinity of flammable materials.
Avo o  e e oe

Avoid complete emptying of the oil tank.
This can lead to air being introduced to
the fuel system and may result in ignition failure.
the fuel supply line to vent. When oil starts to
In negative head oil supply applications the
fuel supply line must be purged using the
screw must be in the tightened position.
oil pump vent screw. For this the oil lter
Open the oil pump vent screw and switch
on the power to the boiler. After 6-7 seconds
the pump has purged the air and the
“CHECK”light will show on the control panel.
The boiler will stop.
Loosen the screw in the oil lter. This will allow
ow re-tighten the screw (this is only possible
in positive head oil supply applications).
and that the low water level alarm is not activated.
of ammable materials.
Voit free boiler call(orange cable)
warning connecting power to the boiler
call will damage the control panel.
Ensure that there is sucient water in the system
Take care when positioning the boiler.
Do not locate in the immediate vicinity
suitable measurement equipment to ensure
Conrm that the ignition and combustion of the
boiler are normal. Use the ue gas test port and
correct combustion is taking place. If the boiler is
power via the controller. Do not plug out the
boiler as this will de-activate the frost protection.
The domestic hot water supply is not
recommended for potable use.(Combi only)
not being used for extended periods turn othe
How to use
20
Purging the oil supply